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(773) 277-1600 | From microcracks to burrs to oxide scale and contaminants, surface imperfections left behind by machining and welding can threaten the fit, function and fatigue life of metal parts, in addition to creating an unfinished or unattractive appearance.
Choosing between electropolishing and passivation at this stage hinges both on what you are trying to achieve and on factors that include the alloy and application.
While both electropolishing and passivation are chemical-based processes, they differ in their benefits, metal compatibility, precision and cost. Passivation removes free iron from the part surface, enhancing corrosion resistance without removing any base material.
Electropolishing removes a microscopically precise layer of surface material, smoothing away burrs and microcracks and leaving parts defect free, corrosion-resistant and passivated in one process.
Whichever process you use, look for a provider who meets standards set by:
Here is an overview of the primary benefits of each process.
Not suitable for parts with extremely tight tolerances and can't allow for a minimum of .0002" of material removal.
Not suitable for metals with lower levels of chromium and nickel which are susceptible to flash attack during passivation, which can weaken the base material and leave the part damaged.
Electropolishing uses an electrolytic solution and an electrical current to dissolve a precise layer of surface material, eliminating burrs and microcracks and leaving behind an ultrasmooth, defect-free, bright surface. Parts are racked to ensure a consistent finish. Electropolishing leaves stainless steel parts 30X more corrosion resistant than passivation, leaving parts in a passive state and meeting the passivation requirements in specifications such as ASTM B912, ASTM A967 and AMS 2700.
During passivation, stainless steel parts are placed into a basket and submerged into a nitric or citric acid bath. Depending on the alloy, acid concentration, temperature, and time are adjusted to effectively remove free iron and other contaminants on the part’s surface. By creating a chromium-rich, passive layer on the part surface, passivation improves corrosion resistance, without changing the appearance. Parts are typically processed in bulk.
Below are results from an independent lab’s testing of four stainless steel alloys after 24 and 888 hours of ASTM B-117 salt spray testing – no rust formed on any electropolished alloys compared, but did form on each passivated alloy.
A set of parts was submitted to ASTM B-117 salt spray testing at an independent testing facility. The test parts included a wire weldment fabricated from 304 stainless steel. The testing was performed for 144 hours on each part in the raw, passivated and electropolished state.
After 72 hours of exposure to the salt spray, the raw and passivated wire weldments developed red corrosion in the resistance welded areas. The electropolished part is rust free. Electropolishing is effective in treating the carbide precipitation condition that occurs in the heat-affected zone during welding. It also improves the chrome to iron ratio on the surface which greatly improves the corrosion resistance.
From implantable devices to surgical instruments, electropolishing is a single-process treatment that results in biocompatible, safe and ultra clean parts.
We offer aerospace vendors and original equipment manufacturers our signature metal finishing services to increase fatigue-resistance for their metal parts, rendering them capable of withstanding the stress and corrosion that comes with long-term use.
Our strict adherence to industry standards ensures that pharmaceutical components are electropolished in accordance with ASTM B912 and ASME BPE specifications. These products are clean and smooth, corrosion resistant and contaminant free.
Corrosion resistance and microfinish improvement are essential for critical automotive parts, making electropolishing an increasingly beneficial option for automakers.
Our metal finishing services help increase corrosion resistance for these parts, and by removing the outermost layer of metal withelectropolishing the durability and longevity of these appliance components is increased.
Electropolishing materials for this industry eliminates the buildup of bacterial biofilms, as well as keeping the equipment free of contaminants like Salmonella. Electropolishing delivers the level of sanitation required by a number of regulatory agencies.
From robotics to mobile equipment, the uses of electropolishing in the hydraulics and pneumatics industry are many. By helping prevent premature part failure, electropolishing reduces downtime and increases the life cycle of these components.
Improving conductivity and performance is just one benefit electropolishing offers for electronics parts. The surface finish is improved by as much as 50%, removing imperfections from the material without material removal.
Electropolishing is a highly controlled electrochemical process that directly impacts surface integrity, corrosion resistance, cleanliness, and performance.
In aerospace manufacturing, electrical discharge machining (EDM) is often the only practical way to create the intricate shapes, micro-features, and tight-tolerance geometries required in high-performance parts. From fuel-system components to actuator housings, landing-gear hardware, and propulsion assemblies, EDM enables precision…
Burrs—those unwanted raised edges, micro-protrusions, and sharp fragments left behind after machining, stamping, or laser cutting—are a common challenge in metal manufacturing.
At the Battery Show and EV Tech Expo 2025 in Detroit recently, the Able Electropolishing team had the opportunity to meet with manufacturers and suppliers of batteries and battery parts across industries that included automotive, aerospace, consumer electronics and medical…
